UK NEWS

Automated self-pierce riveting and studding

Robotics specialist FANUC has supported robot integrator DForce Engineering with the design and installation of two complete automation cells for aluminium underbody components for a prestigious automotive manufacturer.

Leicester-based DForce Engineering has a portfolio of blue-chip clients in the automotive, nuclear and aerospace industries. Among its key customers is Sertec Group, a worldwide business in the automotive sector. The relationship has evolved from jig and fixture design to manufacturing, planning and software design, to full system supply. For its latest project, DForce sought the robotics expertise of FANUC UK.

With the arrival of a new vehicle concept, DForce’s client Sertec required two complete automation cells for the self-pierce riveting (SPR) and self-pierce studding (SPS) of aluminium underbody components as four complete sub-assemblies for its UK automotive production line. At the heart of each cell was a FANUC robot.

Says DForce director Gary Hill:“FANUC robots are a benchmark in the automotive industry. They were a natural choice for this project.”

According to Hill, FANUC’s ROBOGUIDE system was essential to achieving a rapid turnaround: “ROBOGUIDE was used to simulate both the robot’s motion and its application commands, significantly reducing the creation of new motion set-ups. It enabled us to design, test and modify both cells entirely offline, before and during the assembly process.”

As well as reducing design time, DForce wanted to make cost and space savings too, as Hill explains: “We proposed using the larger of the cells with the addition of RH and LH self-pierce studded assembly parts, running three different assemblies through one cell by using a FANUC R2000iC robot. This essentially cut the cost, floor area and cycle times for Sertec by delivering two cells instead of three.”
For further information www.fanuc.eu

Nukon fibre laser proves clear choice

Dunstable-based Steel & Glass Solutions, a specialist in architectural metalwork, has taken delivery of a new Nukon Rex 315 6 kW 2D fibre laser cutting machine from Nukon Lasers UK. The machine was ordered at the MACH 2022 machine tool exhibition in Birmingham, with installation postponed until Steel & Glass Solutions moved into new purpose-built premises.

“Traditionally we relied on outsourcing the laser cutting of high-end polished steel fabrications and steel cladding panels,” says production director Warren Few. “However, these would sometimes arrive with imperfections, meaning they would have to be sent back. Additionally, outsourcing our laser cutting meant we couldn’t always react quite as quickly as we would like to customer needs. We were also aware that having our own fibre laser cutting capability on site would help us to remain as competitive as possible in these times of high energy prices.”

He continues: “Before going to MACH, we had only given a cursory glance to Nukon’s fibre laser machines as, although built in Europe, the brand wasn’t on our radar. However, at the show, we couldn’t ignore the quality, speed and value they offered, or the exceptionally low running costs.”

Steel & Glass Solutions chose the Nukon Rex 2D fibre laser machine for its ability to cut intricate shapes and pieces with speed and precision, supported by fast, easy programming, which is essential for a business dealing with short product runs and complex projects. A Nukon 315 Series machine, the Rex is equipped with a 6 kW nLIGHT fibre laser, with advanced ‘cutline’ beam-shaping technology for high edge quality. The machine also features the innovative Nukon NLCH cutting head that is fully field serviceable, further reducing running costs and downtime.
For further information www.nukonlasers.co.uk

Open house declared phenomenal success

Trumpf reports that its recent open house exceeded expectations. In total, the company welcomed around 200 subcontractors and OEMs to its Technology Centre in Luton, an unprecedented figure in recent years. Trumpf says it secured four orders across several technologies. Among areas of high interest was the company’s new Oseon software, which allows users to automate the flow of factory materials without linking it to a large-scale storage system. Visitors were also keen to learn about new features, such as EdgeLine Bevel, which allows flat-bed laser users to produce chamfers and countersinks in sheet metal.
For further information www.trumpf.com

Material aids nuclear fusion breakthrough

A Cambridge-based manufacturer of specialist metals and materials is playing a key role in the nuclear fusion breakthrough that could change the way the world gets its power.Goodfellow Ltd, which supplies over 6000 customers across the world, provided materials to the Lawrence Livermore National Laboratory in California for the eagerly awaited experiment.On 13 December 2022, researchers confirmed that they have overcome one of the major barriers to producing clean energy from fusion: producing more energy from the experiment than was put in.

“We know there’s a long way to go before nuclear fusion powers our homes,” says Goodfellow’s CEO Simon Kenney.“However, we’re excited to have been able to partner with the Lawrence Livermore National Laboratory to supply some of the crucial materials used in this fascinating and successful experiment.”
For further information www.goodfellow.com

Hyperbat wins major Lotus contract

A UK manufacturer of electric vehicle battery packs has sealed a multi-million-pound contract to supply Lotus with batteries for its new all-electric Evija, said to be the world’s most powerful production car.Hyperbat was formed to bring together Williams Advanced Engineering’s (WAE) EV battery expertise with Unipart’s capability in manufacturing safety-critical products for premium OEMs.

Full production of the battery packs will take place on the firm’s new production line at Unipart Manufacturing Group’s site in Coventry, where the manufacturing process will involve assembling 12,000 components split across 500 unique parts, with 100,000 welds in each pack. The mid-mounted battery pack will support a target output of 2000 PS, and performance targets of 0-62mph in under three seconds and a top speed of over 200mph.
For further information www.hyperbat.com